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52 Flexo & Gravure Global 3-2018 Experience I n many parts of the packaging sector, A&R Carton Graz is proba- bly better known by its previous names MWV Graz GmbH and Alfred Wall GmbH. Alongside to- bacco, which is its biggest business area, accounting for some 75% of sales, the company also makes packaging for chewing gum and textiles. Its customers include lead- ing manufacturers of branded goods in the international tobacco industry and makers of confection- ery. “Our team of 430 staff generat- ed record total sales of approxi- mately EUR 100 million in 2017. Our site in Graz spans 58,000 m 2 and has 36,000 m 2 of production and logistics space that is kitted out with a wide range of machines and equipment for manufacturing packaging materials,” explains managing director Peter Szabó. Everything in one place A&R Carton Graz is one of the few companies that covers the entire value added chain in packaging production. That includes working with customers to develop packag- ing, taking care of prepress (includ- ing in-house production of gravure cylinders and offset printing plates), printing the packaging (sheetfed offset and gravure), and undertaking post-press operations such as die cutting, embossing, hot-foil embossing, and window patching. “We also make the formes for our flatbed die-cutting in- house,” adds Szabó. “The rotary dies are the only things we buy in, and that’s from suppliers we’ve been working closely with for years.” Furthermore, A&R Carton Graz is the only packaging manu- facturer operating in the tobacco sector across the whole of Europe that has an in-house gravure cylin- der production department. The longest printing press in Austria “When it comes to achieving high-quality and consistent results on paper, cardboard, and flexible plastic substrates, the only process- es we would consider using are off- set and gravure,” says Szabó. “The relevant presses are configured in different ways and equipped with a huge range of modules for inline converting operations.” The three gravure presses from Bobst and Cerutti are used exclu- sively to produce cigarette packag- ing and are fitted with inline die-cutters (two of which are rotary while the other is a flatbed type). A&R Carton Graz also has four sheetfed offset presses for folding carton production (one Roland, two from Rapida, and a Heidel- berg). A special highlight of the com- pany’s machinery and equipment is the longest printing press in Austria. It is a 3B format (700 x 1000 mm/27.56” x 39.37”) Speed- master XL 106-10 dual-coating sheetfed offset press which was commissioned in 2014. Installed on a foundation that is 875 mm (34.45 in) high and incorporating UV equipment, the press has been spe- cially configured for high-quality packaging printing. Thanks to in- creasingly complex and demand- ing designs, often very short prod- uct lifecycles, ever shrinking batch sizes and, last but not least, the mandatory illustrated warning no- tices, printing can require up to ten colours. Postpress work on the printed folding cartons and cigarette pack- aging takes place on a total of five die cutters from Bobst, three hot- foil embossing systems, and a huge range of folder gluers and window patchers. Millions invested in gravure cylinder production The Rotoform department at A&R Carton Graz has brought all its pre- press services and cylinder produc- tion in-house. Its total of 80 em- ployees are responsible for manu- facturing gravure cylinders, em- bossing formes, and die-cutting formes. The production facilities serve internal customers and pro- Ansgar Wessendorf Austrian-based A&R Carton Graz GmbH is one of Europe’s leading packaging manufacturers for the international tobacco industry. Rising production requirements and dramatic changes on the market in this area have forced A&R Carton to invest extensively in modernising and extending its capacity for manufacturing gravure cylinders and embossing rollers. Investing in the production of gravure cylinders and embossing rollers A&R Carton Graz GmbH celebrates its 150th anniversary Source: Ansgar Wessendorf The gravure presses at A&R Carton are used exclusively to manufacture cigarette packaging. © by G&K TechMedia GmbH · 79312 Emmendingen · Germany · flexo-gravure.com
Transcript
Page 1: Investing in the production of gravure cylinders and ... · Erhardt+Leimer Automation and Vision Systems Erhardt+Leimer GmbH · Albert-Leimer-Platz 1 · 86391 Stadtbergen · Germany

52 Flexo & Gravure Global 3-2018

Experience

In many parts of the packaging sector, A&R Carton Graz is proba-

bly better known by its previous names MWV Graz GmbH and Alfred Wall GmbH. Alongside to-bacco, which is its biggest business area, accounting for some 75% of sales, the company also makes packaging for chewing gum and textiles. Its customers include lead-ing manufacturers of branded goods in the international tobacco industry and makers of confection-ery. “Our team of 430 staff generat-ed record total sales of approxi-mately EUR 100 million in 2017. Our site in Graz spans 58,000 m2 and has 36,000 m2 of production and logistics space that is kitted out with a wide range of machines and equipment for manufacturing

packaging materials,” explains managing director Peter Szabó.

Everything in one place

A&R Carton Graz is one of the few companies that covers the entire value added chain in packaging production. That includes working with customers to develop packag-ing, taking care of prepress (includ-ing in-house production of gravure cylinders and offset printing plates), printing the packaging (sheetfed offset and gravure), and undertaking post-press operations such as die cutting, embossing, hot-foil embossing, and window patching. “We also make the formes for our flatbed die-cutting in-house,” adds Szabó. “The rotary dies are the only things we buy in, and that’s from suppliers we’ve been working closely with for years.” Furthermore, A&R Carton Graz is the only packaging manu-facturer operating in the tobacco sector across the whole of Europe that has an in-house gravure cylin-der production department.

The longest printing press in Austria

“When it comes to achieving high-quality and consistent results on paper, cardboard, and flexible plastic substrates, the only process-es we would consider using are off-

set and gravure,” says Szabó. “The relevant presses are configured in different ways and equipped with a huge range of modules for inline converting operations.”

The three gravure presses from Bobst and Cerutti are used exclu-sively to produce cigarette packag-ing and are fitted with inline die-cutters (two of which are rotary while the other is a flatbed type). A&R Carton Graz also has four sheetfed offset presses for folding carton production (one Roland, two from Rapida, and a Heidel-berg).

A special highlight of the com-pany’s machinery and equipment is the longest printing press in Austria. It is a 3B format (700 x 1000 mm/27.56” x 39.37”) Speed-master XL 106-10 dual-coating sheetfed offset press which was commissioned in 2014. Installed on a foundation that is 875 mm (34.45 in) high and incorporating UV equipment, the press has been spe-cially configured for high-quality packaging printing. Thanks to in-creasingly complex and demand-ing designs, often very short prod-uct lifecycles, ever shrinking batch sizes and, last but not least, the mandatory illustrated warning no-tices, printing can require up to ten colours.

Postpress work on the printed folding cartons and cigarette pack-aging takes place on a total of five die cutters from Bobst, three hot-foil embossing systems, and a huge range of folder gluers and window patchers.

Millions invested in gravure cylinder production

The Rotoform department at A&R Carton Graz has brought all its pre-press services and cylinder produc-tion in-house. Its total of 80 em-ployees are responsible for manu-facturing gravure cylinders, em-bossing formes, and die-cutting formes. The production facilities serve internal customers and pro-

Ansgar Wessendorf

Austrian-based A&R Carton Graz GmbH is one of Europe’s leading packaging manufacturers for the international tobacco industry. Rising production requirements and dramatic changes on the market in this area have forced A&R Carton to invest extensively in modernising and extending its capacity for manufacturing gravure cylinders and embossing rollers.

Investing in the production of gravure cylinders and embossing rollersA&R Carton Graz GmbH celebrates its 150th anniversary

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The gravure presses at A&R Carton are used exclusively to manufacture cigarette packaging.

© by G&K TechMedia GmbH · 79312 Emmendingen · Germany · flexo-gravure.com

Page 2: Investing in the production of gravure cylinders and ... · Erhardt+Leimer Automation and Vision Systems Erhardt+Leimer GmbH · Albert-Leimer-Platz 1 · 86391 Stadtbergen · Germany

Experience

tion running during this changeo-ver period. We were working at full capacity at the time and we abso-lutely had to meet our customers’ deadlines,” says Granig, recalling the difficult period. “One of the ways we managed was by moving electroplating down to the cellar. We really owe a debt of gratitude to our staff, who showed huge com-mitment in keeping production up and running, including on week-ends and through night shifts.”

The baths for the new electro-plating line were delivered in May and the Cellaxy in July 2017. “July and August were particularly diffi-cult months for us,” says Granig. This was when the new line was in-stalled and the baths that were in the cellar were dismantled and re-assembled. Both production lines had to be run in and coordinated with each other. On top of that, there was the Cellaxy system to in-stall, which was adapted to the re-quirements of A&R Carton in test runs. “Cylinder production was op-erating at full capacity in Septem-ber,” adds Granig. “The fact we completed this major project to plan and without any delay is also down to the service and support we received from Kaspar Walter and Hell Gravure Systems.”

Additional production systems

The laser-etching system from Schepers consists of a 100-Watt Digilas laser, a coating and etching system, the new Cellaxy C500 (600 Watt) and a Schepers laser (250

duction sites belonging to the A&R Carton Group as well as external customers that manufacture pack-aging for the pharmaceutical, con-fectionery, and dairy industries or produce decorative paper and gift-wrap.

“Every year, we manufacture ap-proximately 15,000 gravure cylin-ders in three-shift operation. About 30% of them are for our own needs and the other 70% are delivered to external customers,” explains Ar-nold Granig, the printing forme and gravure cylinder manager. “Three proofing presses are availa-ble to check the quality of the en-graved and chrome-plated cylin-ders. One is equipped with a system for curing UV coatings.”

The gravure cylinders are pro-duced on two fully automatic Kaspar Walter electroplating lines. These consist of electroplating baths for copper and chrome plat-ing, degreasing and de-chroming baths, systems for machining cop-per and chrome surfaces, and laser finishing systems. Three K500 en-

gravers from Hell Gravure Systems are integrated into the first produc-tion line. “Both lines are connected by a shuttle system, which gives us even more flexibility when manu-facturing gravure cylinders,” adds Granig.

Logistical masterstroke

“In December 2016 the decision was taken to invest some 2.5 mil-lion euros in modernising our gra-vure cylinder and embossing forme production,” says Granig, referring to the start of this major project. “We ordered a second Slimline electroplating line from Munich- based Kaspar Walter and the new Cellaxy direct laser from Hell Gra-vure Systems in Kiel. The conver-sion and installation work took from January to September 2017. The first step was to dismantle the old Acigraf electroplating systems right down to their foundations, then make the necessary structural changes. The major logistical chal-lenge was to keep cylinder produc-

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Left: The gravure cylinders are produced on two fully automatic electroplating lines from Kaspar Walter. A cylinder buffer is also integrated.

Right: Arnold Granig, business manager printing formes/rotogravure at A&R Carton Graz

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54 Flexo & Gravure Global 3-2018

Experience

Watt) for direct engraving in cop-per. The laser-etching plant is pre-dominantly used for linework and manufacturing special rollers and embossing rollers, while the Schep-ers direct laser is used to engrave micro-embossing. Two Daetwyler Polishmasters and two CNC ma-chines from Acigraf are used for

geometric machining, i.e. turning, grinding, and polishing the surfac-es of cylinders and rollers.

Cellaxy – a universal tool

“We have predominantly used the Cellaxy to manufacture embossing formes, but we’re making more and

more gravure cylinders with the di-rect laser, too. The first cylinder set was engraved just one week after installation,” says Granig. “Thanks to developments in the gradation range, we can also simulate en-gravings for repeat jobs.”

Contour definition and printing density requirements are often equally challenging in the case of high-quality gravure cylinders for flexible packaging, cigarette boxes/cartons, and packaging for the cos-metic and pharmaceutical indus-tries. The Cellaxy is therefore the ideal complement to the HelioKli-schograph systems for this job mix.

In comparison, the Cellaxy al-lows users to adjust the laser’s screen definition and write resolu-tion independently of each other. For example, text can be repro-duced with very sharp edge defini-tion at a resolution of 2540 dpi and images with a 60 l/cm screen with soft vignettes. What’s more, due to its geometry, the laser-engraved cell transfers a large volume of ink. Thanks to these two effects, gra-vure cylinders lasered using the Cellaxy satisfy exacting demands for both contour definition and high printing density.

The burn-off generated on the cylinder surface during laser en-graving is removed in the Kaspar Walter laser finisher, which is inte-grated into the new electroplating line. This standardised procedure takes little time and is essential to ensuring perfect chrome adhesion.

The optional embossing module gives the Cellaxy all the features it

Milestones – 150 years of A&R Carton Graz1868 Banker August Matthey establishes the company1916 Takeover by pharmacist Alfred Wall1960s Industrial gravure printing is introduced1980s Large-format offset printing is introduced1986 The first Bobst Lemanic gravure printing press for

cigarette packaging goes into operation1987 Cylinder and cutting die manufacture begins1990s The company expands across Europe – Germany,

Poland, Slovenia, UK2001 Acquisition by Westvaco – then MeadWestvaco MWV

in 20022014 The company invests in a sheet-fed offset press,

the Heidelberg XL 106-102015 Acquisition by ÅR Packaging AB2016 ÅR Packaging AB is bought by CVC2017 The company invests in printing forme productionSo

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The two lasers for the direct engraving of gravure cylin-ders and embossing formes –Cellaxy on the left and Digi-las on the right

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© by G&K TechMedia GmbH · 79312 Emmendingen · Germany · flexo-gravure.com

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Flexo & Gravure Global 3-2018 55

Experience

needs to produce 2D and 3D em-bossing formes and supports fully automatic multi-pass engravings with an engraving depth of up to 1000 micron. Embossing produced in this way can create haptic effects and precise reproductions on both large-area micro-embossing and background textures. In terms of quality, availability, and produc-tion speed, the Cellaxy is a highly advantageous alternative produc-tion method to conventional mill-ing and laser technologies.

Embossing Disk software is used to parameterise the embossing job and also calculates the data layers needed for the individual engrav-ing passes. It is normally installed on a separate computer and en-sures embossing engraving work is prepared to the highest standard possible.

When directly engraving em-bossing formes, the engraving depths achieved with each pass on the Cellaxy vary depending on the

material used. In the case of copper, the engraving depth is around 20  microns. Several engraving passes are required in the mul-ti-pass process to achieve the en-graving depths of 150 to 800 mi-crons commonly encountered in embossing. Between the individual passes, both the feed direction and the cylinder’s direction of rotation are reversed. The laser’s focus posi-tion automatically adjusts to the relevant engraving depth and 8-bit greyscale TIFF data is used to con-trol the system. The engraving depth tracks the greyscale data in the image signal with exceptional precision, generating three-dimen-sional contours in each individual pass.

The Cellaxy Embossing is equipped with a wet chamber that stops burn-off from adhering to the cylinder surface by continuously applying a release agent to this surface throughout the whole laser process.

The pinnacle of folding carton production

High-finish packaging is “in” – and that is particularly true of folding cartons, which are currently in strong demand. Like virtually no other company in the industry, A&R Carton Graz has mastered the cigarette packaging segment - gen-erally regarded as the pinnacle of folding carton production.

The company has so far devel-oped and implemented more than 2500 packaging products for the tobacco industry. This achievement can also be put down to its decision to focus the entire value creation process in-house. That includes packaging development, prepress, tool manufacture (cylinder produc-tion, embossing formes, and cut-ting dies), and a comprehensive se-lection of machinery and equip-ment for printing and finishing. “We want to meet the growing de-mand for high-quality packaging by investing in state-of-the-art equipment, such as the new Cel-laxy direct laser and the new elec-troplating line,” explains Szabó. “The fact we produce gravure cyl-inders for so many package print shops shows that our strategy is on course. Numerous awards are fur-ther evidence, such as the German Packaging Award 2016 and 2017, the Pro Carton ‘Carton of the Year 2016’ award, and the German Design Award 2018.”

Left: Three proofing presses are available to check the quality of the engraved and chrome-plated cylinders. One is equipped with a sys-tem for curing UV coatings.

Right: Thousands of gravure cylinders in storage at A&R Carton Graz.

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© by G&K TechMedia GmbH · 79312 Emmendingen · Germany · flexo-gravure.com


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